| NAVAYUGA ENGINEERING CO. LTD. NEC/BTPP/089 BHAVANAPADU THERMAL POWER | Date 27.10.2010 | PROJECT | PROJECT gy A) OBJECTIVE: This method statement describes the detailed procedure to be adopted for installation of bored cast-in-situ piles in the project Bast Coast Energy Pvt. Ltd., 2X660MW Coal Fired Super - Critical Power Project (stage-I) at Kakarapalli,Srikakulam District, Andhra Pradesh, India REV 0 PILING (BY HYDRAULIC RIG) METHOD STATEMENT | B) SCOPE: ‘This method statement is applicable to all the bored cast-in-situ piles to be installed in the entire project using hydraulic piling rigs. Hydraulic piling rigs will be used for boring in all types of soils. These rigs will be deployed for piles having soil boring depth more than 20m, For rock socketing in such piles conventional piling tools will be used. For piles boring depth less than 20m, conventional rigs will be used both for soil and rock boring, C) CONSTRUCTION MACHINERY The construction machinery to be deployed for piling is given below. The list gives the machinery required for one unit of piling. The number of units to be deployed in the project will be according to the approved baseline programme and quantity of piles to be driven.. Piling Equipe 1, Hydraulic Piling Rig 2, Temporary Casing 3, Bucket for Boring 4, Auger for Boring 5. 6 7. Service Crane Tremie Pipe with funnel Bentonite mixing pump 8: Verticat pumps (10-15 HPY 9) Hydra for shifting of cages 10) Service Crane D) SAFETY lll site personne] will wear helmets, safety shoes and other safety devices as required, For other activities such as welding, handling of reinforcement, electrically operated equipment ete. safety devices / precautions will be taken as per requirement, DETAILED METHODOLOGY: 1) SURVEY: ‘The pile point will be marked with reference to nearby control points by using total station and cross checked by measurement tape. The center of the pile will be marked by driving a2) 3) NAVAYUGA ENGINEERING CO. LTD. NEC/BTPP/089 BHAVANAPADU THERMAL POWER _| pate 27.10.2010 PROJECT | PROJECT REV 0 METHOD STATEMENT LE PILING (BY HYDRAULIC RIG) steel pegs into the ground and protected suitably. Normally all the piles in a group are marked at once by surveyor and got checked by ECEPL representative. Before taking up a pile reference points will be provided to the pile center by driving steel pegs on three sides at a fixed distance to enable checking the position of casing and centering of rig. POSITIONING OF RIG: ‘The Hydravlic piling rig will be positioned over the pile center accurately with the help of reference points. The rig will be placed on leveled and firm ground to ensure the verticality of the bore. Rig level and verticality will be checked using a spirit level. CASING DRIVING: Boring will be done initially upto required depth for lowering temporary casing using boring auger / bucket/drill bit, Casing will be lowered into the bore carefully by checking for verticality and center. The casing center will be checked with respect to the reference points and verticality of the casing will be checked using spirit level / plumb bob. Casing top level shall be kept at least 300 mm above ground level. Temporary casing will be provided upto a depth of 12m from ground level. BORING: For boring of the pile boring bucket’ auger and drill bit will be used. During boring, bentonite slurry will be poured into the bore hole to keep the sides of the bores stable. The head of bentonite slurry in the bore will be maintained minimum 2,00 m above the water table, The bored muck will be disposed off at approved dumping yard ‘with cover- protected dumpers. After the boring reaches founding level, further boring “Will be stopped and sounding will be taken with the help of sounding chains to confirm the level. All the soundings and depth measurements will be taken with reference to the casing top, the level of which is recorded before, For piles without rock socketing, entire boring will be completed by hydraulic rig, After reaching the founding level, and checking, the rig will be shifted to another pile location and further activities like cage lowering and concreting will be done by service crane. For pilesNAVAYUGA ENGINEERING CO. LTD. NEC/BTPP/089 BHAVANAPADU THERMAL POWER | pate 27.10.2010 PROJECT | PROJECT REV 0 METHOD STATEMENT PILING (BY HYDRAULIC RIG) for which rock socketing to be done, boring will be done using hydraulic rig and will stop on reaching the rock level then conventional piling rig will be used for boring into rock,minimum socketing will be done into rock 1.5D to 3,0D(D= Dia of Pile) 4) DRILLING MUD (BENTONITE SLURRY): Drilling mud is prepared by mixing bentonite powder with water using mixing pumps and saturated for 24 hours before using for piling. Bentonite in bags is obtained from approved sources and stacked at site in sufficient quantity. The Bentonite received at site will be tested for various parameters specified in the contractual specifications prior to use in the works. Steel tanks of sufficient capacity will be fabricated for storing the mixed bentonite slurry, During the boring bentonite slurry will be poured into the pile bore by pumping with vertical pumps through canvas / rubber hose pipes. The level of bentonite slurry will be maintained above ground water table for a height of about 2,00m by adding up slurry in between. The following parameters for mixed slurry will be measured and maintained. Specific gravity - 1.0410 1.12 Marsh Cone Viscoci = 30-40 see Liquid Limit of bentonite shall not be less than 400% 5) REINFORCEMENT CAGE Bar bending schedule will be prepared and approval from ECEPL representative will be taken before starting of actual work. Reinforcement will be cut bent and tied at the central yard as per the approved BBS and taken to the pilfag focation by truck / trailer or by service crane as per the requirement, The cage shall be fabricated as per bar bending schedule near the pile location. Binding wire of approved quality and size will be used for binding of the cage. Helix reinforcement will be tack welded to the main bars to retain the shape at suitable intervals. Conerete cover blocks (150mm dia) of circular shape with a hole at the center will be threaded on to the helix at a spacing of 2,00m c/c, The size of the cover block will be such that specified cover of 75 mm is obtained. The reinforcement cage will be fabricated in one or more segments depending on the length required. Before lowering the cage into the bored pile, it will get checked by ECEPL representativeNAVAYUGA ENGINEERING CO, LTD. NEC/BTPP/089 BHAVANAPADU THERMAL POWER _| Date 27.10.2010 PROJECT | PROJECT REV 0 METHOD STATEMENT | PILING (BY HYDRAULIC RIG) 6) ‘The approved cage will be lowered into the bore as a whole together or in segments, Service Crane will be used to handle the cage segments, The first sogment will be lowered and held in position by a suitable bar placed across the casing. The second segment will be lifted and positioned over the first segment and the Jap joint will be tied with binding wire, Welding of 6mum size will be done on alternate bars at three places having lengths of 100mm (at Top), 75 mm (at Middle), and 100mm (at Bottom) to ensure that no slippage occurs while Jowering of cage, Helix reinforcement in the lapping zone will then be provided and the cage will be lowered further. process will repeat till all the segments are lowered. ‘The last segment will have suitable hooks for hanging of cage to the easing. Hanging of the cage will bbe done so that the final position of the cage matches with the cut-off level with projection required into the pilecap, FLUSHING: After lowering the reinforcement cage, tremie pipes will be joined and lowered into the bore, Each joint of the tremie assembly will be provided with jute threads and grease to prevent leakage. Tremie lowering will continue till reaching the bottom of the bore. Flushing head will be joined at the top and bentonite pipe will be connected and flushing will be done Flushing will be continued for a minimum of half an hour or till the bentonite slurry coming out of the bore hole and meets the specified consistency, If due to any reason starting of concreting is delayed, flushing of bore shall be continued till pouring of concrete. CONCRETING The concrete of required grade (M30) as per specifications will be produced as per the approved design mix at the centralized batching plant and transported by transit mixers to the pouring location ensuring a slump range of 150mm to 175mm at site, Care will be taken so that the time interval between completion of boring and placing of concrete will not exceed 3 hours. Funnel of suitable capacity will be joined at the top of the tremie pipe assembly. Before the first charge of concrete is placed in the funnel, a floating plug will be14 Date | 27.10.2010 i) | prover PROJECT NAVAYUGA ENGINEERING CO. LTD. NEcBTPP IOS) | BHAVANAPADU THERMAL POWER REV 0 | merHop srateMeNT PILING (BY HYDRAULIC RIG) 8) 9) inserted into the tremie pipe and the mouth of the tremie at top will be closed by a suitable plate, The first charge of concrete of adequate volume will be placed into the funnel before removing the charge plate to ensure flushing action to prevent mixing of water and conorete. Subsequently concrete will be poured in a phased manner, while withdrawing the tremie pipes. Pouring of concrete and tremie withdrawal will be taken in @ careful manner so that always a minimum tremie length of 2.00m is always embedded in the conerete. Regular sounding will be taken to check concrete built up as per calculations. Concrete pouring will be continued till the built-up is minimum 1,00m above cut-off level, Afler completion of the concreting and hardening of concrete the empty borehole will be protected and carefully back filled. Concrete cubes shall be taken for testing of compressive strength as per the concrete quantity involved as per (IS 456-2000). In case Tremie is chocked during concreting, the same shall be extracted and reinserted within 2 hours in the conerete, The concrete shall be continued by inserting vermicular ball in the hopper and filling the same with conerete, Production of concrete will be done as per approved quality plan of it. TEMPORARY CASING REMOVAL ‘The temporary casing will be removed by pulling with the crane as soon as the concreting is completed, ‘The casing will be extracted before initial setting time of conerete, Final level of conerete on top of COL of piles will be checked with sounding chain and will be recorded, 10) RECORDS MAINTAINED i) Bore Log sheet ii) Concrete Pour Cards iif) Concrete batch sheets ") iv) Salient/Distinguished observation made during piling. wpa v) Weather reports \ we a